Process of producing flocked articles



April 15, 1952 w. r3: sAKs PROCESS OFPRODUCING FLOCKED ARTICLES Filed Sept. 20. 1950 2 SHEETS--SHEET l Bix su essa. E

Wa/fer 4Saks INVENTOR.

1 BY an( M25-MM,

`mold form andtothe flock fibers.

variety "of threedimensional articles.

Patented pr. S

`UNITED STATES "PATENT i'OFFICE ItoEs's FPRODUCING FLooKED ARTICLES Waiter R. seks, rorstnins, N.` Y. Application september 20,1950, serialNoblsa'zsa 22 Claims.

This is a 'continuation-impart of applicants copending application entitled EProcess of Producing Flocked Articles, Serial-No. 83,898, filed March 28, i949, now PatentNo. 2,527,501.

`-ln applicants copending application, Ya process "is disclosed and claimed 'for making "double *flocked "articles, wherein the flock "fibers are `sprayed "through `an electrostatic fieldoupon a charged mold form, thendroplets are deposited on the free ends of the "flck b'erswhich form a layer of adhesiva-fand thereafter further flock is sprayed on 'theadhesiveeitlier in or out of the elastrostatic field. The applicant, after continued eiiperinientation, 'has found certain marked improvements in the process yWith "re- "gard to the methods of depositing'the flock fibers, 'the use of certainimproved adhesives, and the methods of applying the adhesivesboth tothe It has `also `been found that theselimprovernents provide a `greater latitude in the'choice of structurally configuration and 4orientation of the fibers.

An important object of this'invention-is to provide aprocess for producing` three-dimensional 1` molded articlescontinuouslm economically, and

with a'minirnuin of manipulative skill.`

As in the"cope`ndin`g` application, the present process contemplates thel production vof flocked 'articles wherein the flock bersare partiallyernbedded in and protrude from a layer of adhesive which forms the sole structural body of the article. p While it is preferred that the ilock'bers be oriented substantially perpendicularlyto all `faces of the adhesive, the process also contemplates the formation `of flocked articlesw'herein the fibers may be voriented at certain Vdesired angles. VBecauseof the nature of the articles produced, it `has been found necessary to'rnodify V'the originalprocess' in `such a manner that the .operator can have a Wider latitude'of choiceof vthe type of adhesives employed, betterccnitrol` of the orientationof thebers `and better control Of the variedrle'n'gths of fibers that "can rbe embedded lin or protrude from the adhesives. The improved process not only affects the con- "trcls mentioned immediately hereinabove but"A also permits of the production of a very Wide Such articles as arglov'e, anat, "pants, a skirt, a jacket,

a'itai'l, a Vbari/hing suit, a "'grdle, and the like *may be produced i inflarge quantities and '-con'l ltinuously by the .method `of the present-invenftion.

Another `object Lof this invention is `toprovide `aprocess of Aforming on `a Inoldpin: onefseres `ora vgroup of connected operations, aI-nished article made in one piece with no seams-either sewn, welded; sealed, or Aput together-in any other manner. rlhe vmai-n structural `body `f the `articles formed is simply an adhesive film `of predetermined `thickness "molded into Aa -desired in and protruding therefrom flock fibers.

lVS7-lille,` as `stated earlieigl the fibers f should be oriented substantially "perpendicularlyj from the uadhesive, for 'decorative` purposes, it-may be "dei -sirable `to orient the fibers'atl controlledang'les `of`fortyto sixty degreesfto the adhesive surfaces. "Processes of electrostatically `depositing lflock fibers on a surface at relatively controlled'angles are ldisclosed yini the Patentsl2,l52,077; 251743328 and 2,217,126.

lfa'ce'of the adhesive.

lfblended, such fas "wool-land rayon, vcotton'and As mentioned 'earlienitis anirnportantobject of this invention y"to 1 provide a process of producing flocked articles Which 'a'llows thefoperator to control `and vary the `lengths-cf the f fibers f embedded in` the' adhesive -as' Well as the lengths of the fibers protruding fromv the surfaces It` hasbeenfound `that when the 'length andfdenier of ltheiibers protruding `from the adhesive l layer orflflm lis varied, the f flocked articles produced 'have `various different characteristics fronithe pointof vievvpfvisual `and physical contact sensation. While the-particular lengths of the bers are not critical, lengths varying from' .015fto .OSO-inch may be suc- `cessfully employed With the `present process. fTheprotruding lengths of the bersmay "be the `same for all surfaces `of the formed :article or may vary from one surfacetofanothr, aswell as the fact that different protruding lengths of fibers may be associated with a given-falce 'orlsln- The deniers i fofV i theI :fibers may 'bevaried along With-the lengths; andfvarious textures of `differentkindsof ockfbersray be -nylon,"etc.

Another object of this invention is tofprovide a process of Aproducing alsingleiiockedfaticle, `iavherein the flock is oriented substantially peryjperidicularly to tlie adhesive, whereinvtlie lengths of the 'bers embedded `in or proti'liding'from the adhesive' can be varied, `wherein the "blend of flock fibers can 'be varied, `and wherein -the adhesive acts as the second sideof` the' flocked article, either as the inner or the outer side of the finished article from the standpoint of commercial desirability.

Another important object of this invention is to provide a process of producing a flocked article wherein the structural body of the threedimensional molded article is fabricated solely of an adhesive and the ock fibers are embedded in and extend entirely through the film or layer of the adhesive with the free ends of the flock fibers protruding substantially perpendicularly from all surfaces of the adhesive.

It has been found, after substantial experimentation, that the adhesive film or layer binding and supporting the ock fibers will, in certain cases, be weak as a result of elongation and flexing. It is therefore another important object of this invention to provide a process wherein the adhesive layer is, in eliect,laminated with two outer layers of adhesive secured 'f-togetherby. an .intermediate layer of adhesive which has a lower coefficient of expansion. In

the-article produced by this process, theock `*fibers are embedded in and protrude at aparticular orientedangle from the outer layers of thev adhesive. Y It is important commercially that certain articles, such as gloves, be fabricated of rubber Aor latex materials inwhich the flock fibers are embedded. It is well known in the art that it l is difficult to ockrubber goods because the adhesive bond between the rubber or llatex and the natural and synthetic fibers is quite poor.

It is, therefore, another object of this invention Y to provide a process of producing flocked articles whereinthe structural body of the three- Y dimensional formed article is formed of rubber or latex which securely binds and supports fiock bers that protrude from the surfaces of the rubber or latex at desired angles of orientation.

The details of the process Vand the variations thereof will be described in connection with the l accompanying drawings wherein: Y

Figure 1 is a flow diagram of the sequentia operations of the process;

Figure 2 is an enlargedsectional view of the Y. mold form and primary adhesive and illustrating the first stage in the process;

Y Y Figure 3 is an enlarged sectional view of the posit of flock fibers and illustrating the fourth stage'of the process; I v A Figure 6 is an enlarged sectional view of the mshed product;

Figure `'7 is an enlarged sectional view of j another form of the finished product or article; vFigure V8 is an enlarged sectional view of the4 primary adhesive, secondary adhesive, and flock fibers and illustrating a modified form Vof the process; Y Y

Figure 9 is an enlarged sectional view of the mold form, primary adhesive, flockfibers. and

secondary adhesive and illustrating a further modification of the process;

. Figure l is an enlarged sectional View of the product resulting from the process illustrated in Figure 9; and

duced within a housing Vor chamber as set forth in applicants copending application, and a mold 4form of any desired configuration, shape or dimension is provided which is charged differently from the eld and is movable and rotatable on a suitable conveyor through the electrostatic field.

'I'he first stage of the process comprises the deposition of a primary adhesive II) on the mold form I2 so that a layer or film of predetermined thickness will be produced on the mold form. Such a deposition can be accomplished in several ways as by spraying the primary adhesive in the electrostatic field as the mold form moves therethrough. The deposition can also be effected by dipping the mold form in the primary adhesive or by spraying the primary adhesive outside of the electrostatic eld.v By controlling the viscosity of the adhesive and the length of time in which the mold form is retained in the adhesive, it will be seen that the dipping process Vwill be anreiective method of controlling the thickness of the layer of the primary adhesive on the mold form and also the strength of the adhesive bond. Because of the necessity of controlling the viscosity of the primary adhesive. it is somewhat more difficult, althoughn possible, to control the thickness of the layer of the primary adhesive deposited on the mold form by the'spray method. The next stage in the process is the electrostatic deposition of the flock fibers I4 Von the primary adhesive. Inasmuch as it is necessary that the fibers be embedded in the primary adhesive and be properly oriented, preferably perpendicularly to the layer of the primary adhesive, the mold form and retained primary adhesive are moved through the electrostatic field. This deposition may be effected by spraying the ock bers through spray guns which are retained in the electrostatic field and are directed towards the moving mold form. This electrostatic deposition can also beV effected y by providing a hopper opening into the electrostatic field,V which hopper is Vfurther provided with aV suitable fiber agitating means and a foraminous member for the separation of the fibers as they are fed by gravity through the hopper and are attracted by the charge on the mold form. Inasmuch as the layer of primary adhesive has not completely set or hardened and still remains somewhat pliable, the fibers will not only be oriented but will also become embedded, in the primary adhesive, The nature of the primary adhesive as well as its viscosity together with the force employed to spray or deposit the fiock fibers will determine the degree or length of penetration of the flock fibers in Vthe primary adhesive. At this stage, the article vdrawings and extending all the way to and in contact withvthe surface ofthe primary adfrancaises iiesive m1throughv'wniehfftheffbersiriproduce, `as shown clearly in thefdrawings. `Itsliould 'be remembered that the Vsecondary adhesive is the one Which forms" the structural body of the4 threedimensional article to be producedby the present process. The physical `and chemical differences vbetween the primary and the secondary adhesive Will be described hereinafter. `The deposition of the secondary vadhesive may beaccomplished by spraying the "same `inthe `electrostatic.Aifield.` If desired, the'inold form canfbe moved outwofV the electrostatic field `and the secondary *ladhesive can be sprayed thereon" or the mold form with the associated primary adhesive `and `retained `flbersrcan 'bef dipped `in a Y` solution of f the secondaryv adhesive "wherein the viscosity and time of contact Withthe secondaryadhesive canbe controlled effectively-to obtain a `desired and predetermined'thickness of fthe secondary adhesive. i It will,` ofcourse, lbe understoodfthat the thickness of the secondary adhesiveishould be controlled,` depending uponthe nature of the articles to be produced.` Note* should bei taken of the'fact -that the length of the fibers I4`pro truding from the primary adhesive layeriIIl de.`

termines the `length or degreeofpenetration of -these fibers' in the secondary adhesive, inasmuch as the secondary `adhesive extends tothe `point of `contactwith the primary adhesive, as

lengths and the fibers themselvesmay lbe wool, i

rayon. cotton, nylon, and the like, "or any desired blend thereof. Such blending 'of the lengthsand kinds of fibers can be readily `effected either in the spraying mechanism or in `the `hopper gravity feed described hereinabove. i i

The fourth stage of the processk comprises the electrostatic depositionof flock I8"-on'the adhesive layer I6. As in the first fdepositionof the flock. the further flock fibers I8 can be deposited upon the secondary adhesive IBbyspraying the same in the electrostatic field "by spray guns or by an agitated gravity feed through a hopper having a foraminous member to separate the bers. When it `is desired `that the further flock fibers I8 `be oriented `relative to the layer of the secondary adhesive, the'deposition must take place in* the electrostatic" field. `However, since the bers I4 have been `deposited in the electrostatic field and are properly oriented with regard to the primary adhesive layer I and also to one face ofthe secondaryadhesive I6, it is not necessary in all applications that the further flock fibers I8 be oriented relative to the other face of the secondary adhesive in the same manner as the first flock fibers I4 were oriented. Inasmuch as the final product, as shown clearly'in Figure 6, Willbe a predetermined thickness of a layer of secondary adhesive I6 having embedded therein and protruding` from all faces thereof the fibers I4 and I8, the three dimensional molded article will have inner and outer faces that are fiocked. rIn most cases, the three-dimensional articles inthe form of wearing apparel should :have the flock fibers' I4 and I8 oriented substantially perpendicularly"'from the lthree of thev process,the secondary adhesive may be'curedand set, the moldform discharged andl "the fiocked article stripped fromthe mold form, "and then thelprimary adhesive is appropriately Hence,' thel furtherflock `I 8 may be 'deposited on 'thesecondary adhesive I6` outside of" the electrostatic field.

"The fifthstage f'thepro'cess usually involves thelc'zurin'gl and 'setting' off' ther secondary' adhesive *while theflocked articler is-""still`f-retained 'upon '-thecharg'edfmold form. Thecuririgjandlsettng temperatures 'for the"`s`ecoiidary adhesive will, in "most cases,` be `different V'from fthe c'uririg and setting l:temperatures of "the fpriinary adhesive because of #the chemical differences between these'two adhesives, although it is not essential 'that "there "be a substantial difference Ybetween the settingiand curing temperatures of the seciondary "adhesive "and fthe -`primary adhesive "Physically, 'the curingfand setting is eifectedby passing the article onthechargedfmoldlform 'through a'suitable heating chamber and then, if

" necessary, through a suitable cooling chamber.

The nature of the curing `operation will depend `upon the chemical composition of the secondary adhesive fand Whether lthesecondary adhesive vis either a thermosetting, ai thermoplastic, ora

mixture Jof thermosetting and "thermoplastic plastics. Y i

The sixth stage of theprocess includes stripping `the article fromthechargedmold:by removing t -e electrical'potential on" the lmold and physically lifting off theflocked article from the uncharged mold form. `In someapplications, it is possible to discharge the mold form i and striptheflocked article from themold'form before the secondary adhesive iis completely cured and set.

The last stage of the process comprises the removal ofthe primaryadhesivelayer l0 to expose a predetermined length of theendsof the bers 14, asishown clearly in Figure 6. The methods of removingthe primary adhesive fromthe fibers IlIand the-secondary adhesive I6 lwthoutaffectingl the bondingsupport ofthe fibers I4 Tand I8 in the secondary adhesive I 6 depends upon the chemical nature of the `p'rima'ry'adhesive `employed. `Such removalmay be effected bymechanicalstri'pping `where the primaryadhesive is ofr a strip coat formulation, or,`the primaryadhesve'may beremoved' by washing in hot or cold water or Washing in a Ahot or cold non-aqueous solvent, it being 4understoodthatthe hot or cold Water andthe hot or cold solvents wllhave substantially nosolub'ilizing effect on the secondary adhesive.

helsiveand protrude in an oriented relationship through but oneface or .surface of the adhesive,

as shown clearly in Figure '7,the above-described process can be carried `out'vvithout the steps of depositing the further flock I8 on the secondary adhesive. In thiscase, thereforaat the stage removed to" expose the "ends ofthe "flock fibers A ofjilcck -ilbers of .varying length.

iii. 4'lecause ,the .orientation 4ofthe fibers, their length, andtheirdegree of penetration in the primary adhesive can be `controlled as described ,hereinabove, a single flocked article can be readily produced in which the Vsecondary adhesive forming` the structural body of the three-dimensional formed article can be of a controlled thickness andthe iibersA I4 can be retained therein in varying degrees of penetration. Such a singlerflocked article can therefore retain a blend or mixture of different forms of'ilock `fibers `andalso a mixture It has been found that 4when a ,given surface .of the adhesive has protruding therefrom or embedded therein n a mixture ofr different lengths of ock fibers, the

v isualand tactile texture is far different from t that of an article in which the bers are all of thesame kind and of the same length.

Another-method of making the article shown in Figure 7 is illustrated in Figure 8 and comlayer of primary adhesive. I of predetermined V thickness and then depositing upon the primary adhesive a layer of secondary adhesive I6 of predetermined thickness followed by the electrostaticdeposition, either spraying or gravity feed, of flock fibers I8 on the secondary adhesive I6. The chemical nature of the secondary adhesive, its Viscosity and its tackiness, will, in conjunction with the force of sprayor deposition of the flockI thickness of one surfacecfthe Scndarf adhe sive may-be removed with a solvent therefor fto expose a predetermined length of bers, as at ZIJ. Thereafter, the secondary adhesive Yis cured, the article is stripped VVfrpm the mold forni, land the primary adhesive is removed from the secondary adhesive and the fibers to produce the article as shown in Figure 10.

The above described methods of making ,flocked articles permit .the Voperator a Wide latitude in the choiceof VYsecondary adhesives and also gives the operatcr good controls for varying the thickness of the secondary adhesive. At certain times because of the thickness of the adhesiveand the chemical Ynature thereof, elongation and lflexing o f the secondary adhesive will set Y up stresses and strains therein to weaken the prises rst depositing upon the mold form I 2 aA` bers "I8 dete rmine the extent or degree of pene# tration of the flock fibers in the secondary adhesive. As in the previously described processes,

the secondary adhesive may be properly cured and set and the primary adhesive removed either mechanically or by solvents to produce the end" product as shown in Figure '7.

A double flocked article of exceptional strength can be produced by another modification of the present process and will be described in connecaxes ofthe Vfibers in such a manner that the sec- I ondary adhesive does not completely Vcover or embed the fibers but, rather, permits a predetermined length of the fibers, as at 20, to protrude from the face of the secondary adhesive opposite to the face which contacts the primary adhesive I0. cured and set, the mold form discharged and article stripped therefrom, and the primary adhesive I0 is removed from the bers and the secondary adhesive by mechanical stripping or so1- vent action to produce'the article shown in Figure lOlwherein the fibers extend .throught the entire thickness of the layer of adhesive and protrude from the inner surface 22 and outer surface 24 of the adhesive substantially perpendicularly thereof. It is manifest that such an article will be quite strong and durable and the possibility of pulling out or dislodging the bers will be quite sma l.

'The above-.described article can be made in several other ways. Thus, for example, the secondary adhesive I6 may be deposited upon the free ends of the elongated nook bers I4 in such a manner that the secondary adhesive completely covers and embeds the fibers. A predetermined adhesive. To overcome this disadvantage, the above processes may be varied in such a manner that the secondary adhesive becomes, in eiect, a laminatedstructure. Thus, after stage three as illustrated in Figure 4, a third layer of adhesive 26 of predetermined thickness may be deposited upon the free surface of the secondary adhesive I6 and then another layer of secondary adhesive Ilmay be deposited upon the free surface of the thirdv adhesive 2,6. Thereafter, the further flock fibers I8 may be vsprayed upon or deposited by gravity upon the exposedsurface of the second layer of secondaryV adhesive I6. Thereafter, the secondary andthird adhesives are cured and set, the article stripped from the mold form, and vthe primary adhesive lremoved to produce the articleas shown clearly in Figure 1l. The third adhesive is chosen Vto have a lower coeflicient of expansion than the secondary adhesive so'that the stresses and strains on the secondary adhe- V sive resulting from elongation and flexing will be materially reduced. Note should be taken of the fact that even this article has inner and outer layers of ,flock protruding in oriented form from an adhesive which is of laminated structure. It is evident thatthe third or intermediate layer of adhesive 26 constitutes a reinforcement for the .i secondary adhesive, but it will be seen that this The secondary adhesive is then reinfcrcement is not in the form of a textilematerial orA other,backing but simply another predetermined layer of adhesivehaving a lower c oeiicient of expansion than the outer layers of adhesive.

It is commercially desirable that certain articles be fabricated from natural or synthetic rubber or latices, as, for example, gloves, work clothes, girdles, bathing suits, boots, etc. It is well known in the Vart that it is diicult to securely retain natural and synthetic flock fibers in rubber adhesives because the bond between the fibers andthe rubber is quite weak. The present methQd'm-ay be varied and adapted to produce flocked rubber .articles wherein the fibers are held securely in the rubber or latex adhesive and Vovercome .the above-mentioned disadvantage. A

.and oriented substantially perpendicularly thereto. As analternate method, the coagulant may be sprayed or `dipped onto the primary adhesive anemona which maybepreviously deposited up'onthemold form, and then flocked ini theelectrostatic'field'.` 'Thereafter the `mold form, with` the Viiockizibers embedded in theprimary adhesive tand. coagulant thereon, isdippedinto al, latex dispersion comprising; relatively small solid particles,and left there for fapredetermined lengthnftimefin order that the Vparticles may buildzup.- and yet'leave. a predeterminedfportion i of the free ends of the fibers protruding from the rubber or latex.` The. rubber er` latex particles cohere upon contacting the coagulant and deposit and'build up solid paiQ`` ticles upon the surfaces ofthe coagulant and between the fibers. To increase the adhesive bond :between the rubber-or latex layer and. the iibers,y additional adhesives may be included in the latex dispersion, saidadhesives being compatible. Adhesives containing Vpolyvinyl butyral or casein havelbeenV foundeifective. After the rubberor latexY layer hasbeen' cured, the article is` stripped from themoldzform andthe primary adhesive removed-so that the article'resembling that shown in Figure 110 is produced wherein'the material supporting `thexiibers will be a rubber or latex. When relatively thin layers of' rubber orA latexare Idesiredit maybe desirable to'iuse thesurface of the primaryl adhesive whichprotrudes betWeenthe-oriented flockV as a' coagulant;` the adhesive catching and holding the-solid `latex'` particles that come-in contact with it, and'subsequent particles cohering thereon. Ittis conceivable that this coagulation process may be. employed to advantagewith plastics otherfthan` rubber or latex.v

The detailsV ofthe conditions necessaryfor carrying. out `the above-described processes will` be set .forth.immediatelyhereinafter: As mene tioned earlier, .various combinationsfof lengths,v colors, and kindsofbers'may be-employed in the present process, the only limitation on thes combinations beingithat `the length', deniezyand` kind ofiibersrbe such that"they'canrbevproperlylf oriented-in Aan electrostatic 'iield relative'` to the` adhesivetlayersupon which the-fibers `are .to `be supported. The` iibersmay be of natural origin; su-chas silk, ramie,cotton, wool, hairyandother: types ofL-.bersor they may be synthetic, as vis` coseand acetate rayon nylon, orlon, vinyl bers, i

andthe like; Itshould be r rememberedA that there isa marked difference between the `flocked' surfacecontaining bers of thefsame denier'oriented substantiallyA perpendicularly tothe adhesivesurface. when the length of i thefbers isf. varied. Thus, `for example, a surface-containing` iickwhichextends .015,in. from the surface as compared to .one which has nook which extends. approximately .002.to .010 inch differs-markedly` in .color andfeel, thefshorter fiockfsurface being softer and more like suede. It has` also been` foundthat a combination .of the same type-` of fiber using diiferentlengthsmay-be employed, such as a mixture of approximately60%` .020 inch viscose rayon and `40% of. approximately '.040inchl viscose rayon, both fibers being of the same denierf.` The feel and appearanceof `thispile fabric-,is entirelydiiferentthan the` fabric-employing 100 .of Variation:v of. the v -40. ratiohasbeen `found to4 produce a-softer feeling'` either of,` these fibers.

and softeriloolringy pile.-

With-regard-to the type of electrostatic iield 1 employablein ,the presentrprocesait is conven-A tionalto electrostaticallw deposit flocknbers in-` a` field of alternating` current where thefiibers .sive is cured and set.

are fiinallyyembedded fin' they adhesive, the charge onrthe moldform being-:of suchfmagnitute :as :to sufficiently hold. the' iibersA on thevthin` film of primary adhesive: A'stthe art has. recognized; direct" current may beremployed to establish the electrostaticzeld; and,` inV sucha case,v the `flock bers soften'ctend to" string out: betweenvtheelec-i trodesand short-out the system. However, since, in certain.` applications,` it is fdesirableand necessary;` to `sprayfth'e` adhesives on themold" form through the-electrostatic iield,to allow the adhesivev particles'orrdroplets to jump through the electrostatic field `andfstay'securely on the mold form,it may fbe desirablertoA use av direct current electrostatic 'eldai` `Thus,= inY the present basic process, itA may beadesirable,` although not entirely necessary;` totde'positztherst or primary adhesive.` on the'rmoldformzthrough'the direct current 1electrostatici'eld,'. toardeposit `the iirst layer of flock on the adhesive through an alternating current electrostatic iield, to deposit the f secondaryr adhesive uponrthe free:ends of the fibers through at directv current' electrostatic held; and to finally depositthelastlayer oi. iiock upon `the secondary adhesive through an alternating current electrostatic held.

Asis obvious from` the above discussion' ofthe present process, the primary and secondary ade hesves must differ" from each ,other. and, `with regardto the-form of `the: invention illustrated in Figure l1, .thesecondaryfadhesive mustdiiier from the third orV intermediate layer'of adhesive. Therelationship or difference between the primary and secondary adhesivesmustbe as follows: i

1. The primary adhesive must be weaker than the secondary adhesive in. bonding characteristics or properties topermit 'the ready and easy removal of the layeraof primary adhesive from both the oriented fibers andthe mold form` The secondary` adhesivemust have strongbonding characteristics, inasmuch as it willlbe `the structural body` ofY the .three-dimensional molded article which will securely retain thebers;

Z'Both the. primaryand'secondary adhesives must be capable .of properly orienting the bers.

3. The formulation of` the primaryv adhesive,y must be suchthat it does not retain a latent solvent which will'blow before the secondary adhe- Such blowing of latent` solvent maydislodgesome of the fibers and may also upset `the orientation thereof.

4. The formulations ofthe primary and. secondary adhesives -must be such that there will not be any chemical interaction between them, substantially no miscibility, and substantially no migration of the adhesives.`

` 5'. While Ait is preferredthat the-primary adhesive bein `the formof a strip coat that could be mechanically removed, the present invention also contemplates the use of aqueous and nonaqueoussolvents for the` removal ofthe primary adhesive. In the latter case, the formulation of thesecondary adhesive should tbe such that the solvents employed for removing the `primary adhesive should havesubstantially no solubilizing eiect upon thesecondaryadhesive. In this connection, the formulations ofthe primary and secondary adhesivesshould `be correlated with certain types of' fibers whichY would not unnecessarily -absorbl andrbecome` swelled by theV solvents employed for removing the primary adhesive.

`The primary" adhesives that lmay be employed to; advantage -in the present process ,l are as follows:

1. Aqueous solutions of natural gumsV such as tragancanth, karaya, arabic, etc. adjusted to desired viscosities. The solutions may be modified with wetting agents, non-drying oils, and tacklers well known in the art. These solutions are generally in the form of a gel which, when heated, changesto a sol and the cold mold form may be dipped in the hot sol, or, the hot sol may be sprayed upon the cold mold form. Such a dipping sets up a gel on the surface of the mold form and the viscosity of the solution and the length of time of dip will determine the thickness of the nlm deposited as a gel upon the mold form. The concentration and nature of the modifying agents will determine the tackiness of the film. 'Ihis type of primary adhesive can be removed by hot or cold water, it being understood that a secondary adhesive would be ernployed therewith which is substantially soluble in hot or cold water.

l 2. Aqueous gelatine solutions may be employed as the primary adhesive which can be applied toV the mold form by a dip or spray technique, the layer of gelatine formed as the primary adhesive being removable either by heat alone or by hot or cold water, the heat or cold water having no melting or solubilizing effect on the secondary adhesive employed.

3. Modified cellulose bases may be employed as the primary adhesive such as carboxymethyl cellulose in water and'methyl cellulose in water. The' application and removal of this type of adhesive ls the same as that described in paragraph one above. An illustrative'example of a formulation which can be employed to advantage in the present process follows.

When the above formulation employs carboxymethyl cellulose, hot water is employed to dissolve the adhesive, and when the formulation uses methyl cellulose, water at room temperaturemay be employed as the solvent.

4. Natural and modified starch base adhesives may be employed as the primary adhesive as well as water dispersible protein adhesives, such as hide, bone, lish glue, casein, albumen, etc. For-V mulations including alginates, as described in the Patent 2,491,258, may also be employed. When these adhesives are employed, the hotdipped primary adhesive forms a gel and becomes tacky on cooling and does not need the addition of nondrying oils and wetting agents. Hot or cold water maybe employed to remove these adhesives.

, 5. Adhesives may be employed for the primary adhesive formulation which include polyvinyl alcohol Ywhich are easily removed from the bers and the secondary adhesive by hot water.

6. The primary adhesive may be formulated'of a coating or an adhesive removable with nonaqueous solvents. For example, coating solutions of acrylate and methacrylate resins form excellent coatings which can be removed by such solvents as ketones, esters, chlorinated hydrocarbons, etc. `Cellulose acetate coatings may be employed which are removable in such solvents as ketones and chlorinated hydrocarbons. Ethyl cellulose coating compositions may be employed which are l2 removable bysuch solvents as alcohols, esters, aromatic hydrocarbons, etc. The vinyl acetate, vinyl butyral, vinyl chloride, and othervinylresin coatings, except vinyl alcohohmay be employed, which are removable by non-aqueous organic solvents. Reference is made to `the publication Modern Plastics Encyclopaedia, v1947, for the exact formulations of these coatings or adhesives and the exact solvents to be employed for their removal. Y

7. A strip coating formulation maybe employed as the primary adhesive. Conventional plasticized ethyl cellulose strip coatings-may be applied as a hot dip to the cold mold form and the fibers deposited upon the adhesive 'while' the coating is still hot. After cooling, the coating may be stripped mechanicallyfrom the fibers and the layer of the secondary adhesive. Compositions such as the pressure-sensitive type of adhesive may be employed, as well as the types of adhesives described in the Patent No. 2,222,539. These latter compositions may be used in a tacky semi-dry state, flocked with fibers in such a stataand dried before they are coated with the secondary adhesive. A

The secondary adhesives may be thermcsetting plastics, thermoplastic plastics, or mixtures thereof, the following being examples of the types of materials which may be employed as secondary adhesives in the present process l. Plastisols which are vinyl chloride-acetate resins having a high enough proportionof plasticizer to be the sole dispersing agent so that Yiuid. coatings can be made which have no volatile constituents. The plastisols are converted to a tough, rubbery film by heating to S25-350 F. The physical and chemical properties of the plastisols are described in the publication Modern Plastics, April 1949, pages 78-80, and in the Technical Data booklet entitled Vinylite Resins Dispersion Coatings, published by the Bakelite Corporation, and copyrighted in 1949. y Typical dispersants are esters, ketones, glycol ethers, and aromatic oraliphatic hydrocarbons may be used as diluents if desired. In using the plastisols as the secondary adhesives, it is preferred that they be deposited upon the free ends of the fibers retained in the primary adhesive by a hot 0r cold dipping process. If extended with the proper diluents, the plastisol may be applied by spraying in or outside of the electrostatic eld. As will be manifest, the

' plastisols can be used as the secondary adhesives in Vconjunction with the water soluble primary adhesives listed hereinabove, the strip coat primary adhesives, and those primary adhesive coatings which are soluble in a non-aqueous solvent which does not solubilize the plastisol. The viscosity of the plastisols can be readily and easily controlled and, accordingly, the thickness of the film formed on the surface of the` primary adhesive can be controlled by a correlation of the vis-Y cosity, the temperature of the mold form, and,A

i iai strengthllnn.. Theforganosolsfare:alsorfullyxdewi scribed in?theipublioationsihereinaboyei referred's toin'cconnectionwith the1p1astisolsi Thaorganos` A sols mayberfcombined-with allfofi the primary ad:

hesiveslistedlhereinabove the samecmanner the `plastisols;,but` arer less."` desirable than-theo plastisols because `ofitlfi'efsolvents.evaporation `land Ll disposal..problem;`

3.' `Solutionsof snylorr V-inayibe employed as `the secondaryfA adihesiveiin''faz .l formulation 'i containing. i

ten to twenty per cent by weight of nylon,:1^ive:-

per -cent rcby weight ofv citric acid; and..." the remainderA ethyl or isopropyl i alcohol Water:

The ratio ofthe alcohol tofthewwater is 170.tof-30s by volume. When: the mold iform retainingwth'e` primary iadhesirve vand the `fiockblfibers iaretdippedf in this Inylon solution; a: film will form fwhichi can7 be fairfdriedandfused at temperatures somewhat f below` 212 Ff to:insolubilizefthe:nylon. Ity evident that such nylonrso-lutions=can besemployed to i advantage ini i combination i with the water soluble 'primary adhesives vhereinabove described? 'is Aqueousesolutions of polyvinyl i alcohol tof which "has been' added -"dimei'li-ylol ureaior chromate salts may be-AY employed thesecondary* adhesives -which form-f a film that can'A bej air orv'i force driedinlan oven.` The films formed' are not water-soluble Aand i may lbeedisintegrated*or dissolved only by certain organic solvents. There--A fore; this adhesive coatingcan be properly=com bined :withV Vtheprimary adhesives f Vpreviously set-A forth.

5: Ther-adhesive coatings-A requiring non-aqueousf solvents described under" the primaryH ad-V hesives yhereinabove scan? of Course; be-'einplciyednl as f secondary adhesives when the `primaryl ad'- hesive is of a4` waterJ soluble formulation; Examples" of such* vadhesive coatings are-ethyl cellu losey cellulose-acetate;` the vacrylatea' and' the vinyls,` as well-as ,otheradhesives aforementioned* or describedin Patent No. 2 ,22235391 6J Vinyll solution adhesives emayj ben employed in certain applications secondary adhesives:

Withregard to the nature of the third adhesiven used to" laminate the secondary adhesive, as shown clearly in Figure 11, ,the only requirement is that the thirdadhesive'have a 4lower coefficient ofi.` expansion tiran .the secondary adh'esiveto;A relieve the latter of the shock andistresszresulting from elongationfandfflexingi The. third` adhesive may be formulated from an organosol modifiedA with. a-yinylite resin VAGH. a'inaterial soldloythe` Bakelite .Corpo-ration which contains by,I weight approximately 91%' vinyl chloride, approximately 3 vinyl acetate,` and 213% hydroxyl in the-form of vinyl alcohol. The third adhesive may also be formed of an organosol modified with polyvinyl butyral or an organos-ol or plastisol modified with an acrylo-nitrile adhesive.

Thus, it will be seen that ia novel and effective process has been provided for making flocked articles wherein the structural body of the articles is fabricated solely of an adhesive supporting oriented flock fibers which protrude from one or more of the surfaces of the adhesive. The process permits the mass production of the articles and also permits the operator to control the penetrating as well as the protruding lengths of the fibers, the orientation of the fibers, the nature of the adhesives, the blending of different kinds, lengths and deniers of fibers to obtain a variety of tactile and color effects, and so forth.

While a preferred embodiment of the invention has been described and illustrated hereinabove, it should be understood that one skilled in the vente:diluentsf` and otherliquids :whichwill create an adhesive ,-.iilm inasitu on the Tmold:foririzq` Also;

the choice of primary adhesives having relativelyN 5higlirsolid:contentsfwillniinimize the Aproblem of solvent absorption'byithefibers;.

Havingidescribed theLinvention,` what isclaimcd*A as new. is

1:, A. processi4 of' producingv ag. flocked article Y comprising: depositing` primary adhesive ,i on ai mold. form;` .electrostaticallyr depositing `andizemizbedding@flock:-` flbersirr said primary adhesive;

depositing `awsecondary adhesive. on the;` fibers;-A depositing further flock fibers on the secondary-s" fadhesive; stripping .ztheflocked article` from .the mold form,L andzremovng the primary adhesives 2. The processifofclaimulwwhereinr the'moldw form is maintainedfin` air electrostatic `eld and charged diiierentlyi from `the field; said` fprimary:v

adhesive being4 deposited` on the charged mold:

formsrby :spraying in the electrostaticfield.`

3." Theiprocess of claim 2 wherein the second-` ary adhesive is :deposited on the fibers `by r sprayi ing linv thel electrostatic f field.;

4: Theprocessfsof claimi 3 "wherein :thef `further flock'iis i depositedf'lonthe-secondary iadhesive by i spraying Ain the=electrostatic fields'.-

`5. The process of Dclaim 1 1 whereirrtheprimaryv adhesive is deposited on the' moldiformibydipping thelatter into the print-laryadhesive.`

6.* The processiof claim 1 whereinthesecond ary adhesive List-deposited on the fibers by" dipping the mold formi-1 carrying the primary adhesive and `fibers fin* thezfsecondary#adhesivef 7. A process of producing a flocked article comprisingwproviding an electrostatic field and a moldlformcharged `differently from` the field and1movableHtlieretlfirough;` spraying Aa primary' adhesive onthemold form outside the field; 'moving; the mold formuthrough 'i the field and depositing Vand embedding flock berein" the` primaryadhesiveinI the field; spraying `a second ary adhesive on thel fibers outside the i field,` depositing further a flock on the Y secondary ade hesive, strippingfthearticle vfrom the mold form',

andoreinoving `the 4primary adhesive.

8: Theprocess .ofrclaixnc'l wherein the. further; flock is deposited orr" the "secondary" adhesive 4by spraying inthe electrostatic field.

9.* Theprocess Aof clainr'lwherein the further flock fibers -`are deposited' on" the secondary Aad-"- hesive by spraying outside the electrostatic field.

10. A process of producing a flocked article comprising depositing a primary adhesive on a mold form, electrostatically depositing and embedding fiock fibers in said primary adhesive, depositing a secondary adhesive on the fibers, depositing further iiock fibers on the secondary adhesive, stripping the flocked article from the mold form, and removing the primary adhesive by a solvent for the primary adhesive which has substantially no solubiliaing effect on the secondary adhesive.

11. The process of claim 10 wherein the solvent is water.

12. A process of producing a flocked article comprising depositing a primary adhesive on a mold form, electrostatically depositing and embedding flock fibers in said primary adhesive, depositing a secondary adhesive on the fibers,

depositing further flock bers onv the secondary adhesive, stripping the flocked article from the mold form, and removing the primary adhesive by mechanically Astripping off the primary adhesive from the first layer of bers and the secondary adhesive.

13. A process of producing a flocked article comprising depositing a primary adhesive on a mold-form, electrostatically depositing and embedding flock fibers in said primary adhesive', depositing a secondary adhesive on the fibers, depositing further ock fibers on the secondary adhesive. stripping the flocked article from the mold form, and removing the primary adhesive, the primary adhesive having weaker bonding properties than the secondary adhesive so that the primary adhesive is readily and easily removed from the mold form and first layer oi bers.

14. The process of claim 13 wherein the primary adhesive is not chemically reactive and misciblewith the secondary adhesive.

15. A process of producing a flocked article comprising depositing a primary adhesive on a mold form, electrostatically depositing and embedding lock iibers in the primary adhesive, depositing a secondary adhesive on the bers, said secondary adhesive completely covering said bers and contacting saidprimary adhesive, removing a layer of predetermined thickness from said secondary adhesive to expose'a portion of said fibers, stripping the article from the mold Y form, and removing the primary adhesive to expose another portion of said fibers.

16. The process of claim 15 wherein the resecondary adhesive is accomplished by the application of a solvent for the secondary adhesive to the surface thereof opposite that surface contacting the primary adhesive.

17. A process of producing a flocked article comprising depositing a layer of primary adhesive on a mold form, electrostatically depositing and embedding flocked fibers in the primary adhesive, depositing a layer of secondary adhesive on the bers, depositing a layer of a third adhesive on the secondary adhesive, said third adhesive having a lower coefficient of expansion than said secondary adhesive, depositing a further layer of secondary adhesive on the third adhesive, depositing further flock fibers on the further layer of secondary adhesive, stripping the article from the mold form, and removing the primary adhesive.

18. A process of producing a flocked article comprising providing an electrostaticfield and moval of a predetermined thickness from said 16 amold form charged differently 'from the field and movable therethrough, depositing a -layer of primary adhesive on the mold form, feeding by gravity through a foraminous member an agitated mass of flock fibers for depositing and embedding the bers in the primary adhesive, and then depositing a secondary adhesive on the fibers, depositing further flock fibers on the secondary adhesive, stripping the docked article from the mold form, and removing the primary adhesive.

19. A process of producing a flocked article comprising depositing a primary adhesive on a mold form, electrostatically depositing and'embedding flock fibers in said primary adhesive, depositing a secondary adhesive on the fibers. depositing further ilock fibers on the secondary adhesive, curing the secondary adhesive, stripping the flocked article from the mold form, and removing the primary adhesive. n

20. A process of producing a flocked article comprising dipping a mold form in a primary adhesive, electrostatically depositing and embedding flockbers in said primary adhesive.

`dipping said ocked form in a secondary adhesive, depositing further flock fibers on the secondary adhesive, stripping the flocked article from the mold form, and removing the primary adhesive.

21. The process of claim 20' wherein the further iiock is deposited on the secondary adhesive by spraying in the electrostatic field.

22. A process of producing a flocked article comprising depositing a layer of primary adhesive on a mold form, electrostatically depositing and embedding flock fibers in the primary adhesive, depositing a layer of secondary adhesive on the bers, depositing a layer of a third adhesive on the secondary adhesive, said third adhesive having a lower coefficient of expansion than said secondary adhesive, depositing further ilock fibers on the third adhesive, stripping the article from the mold form, and removing the primary adhesive.

WALTER R. SAKS.

REFERENCES CITED The following references are of record in the le of this patent:

Saks Oct. 24, 1950 

1. A PROCESS OF PRODUCING A FLOCKED ARTICLE COMPRISING DEPOSITING A PRIMARY ADHESVIE ON A MOLD FORM, ELECTROSTICALLY DEPOSITING AND EMBEDDING FLOCK FIBERS IN SAID PRIMARY ADHESIVE DEPOSITING A SECONDARY ADHESIVE ON THE FIBERS, 